Soap treating apparatus



2 Sheets-Sheet 1 Filed Jan. 13, 1947 a W w za w m 3 fe U 7 .w W 21v 45 S 53 e 5 .MI (/54526 Z .W 3 M 3 I A 9 4 .n o m7- W o o wo uw 3 U z w w LW w Alfa /zv w w I 2 Z Z 9 W 5 Oct. 10, 1950 L. scHuu-:RUD

soAP mm'rmc APPARA'rus 2 Sheets-Sheet 2 Filed Jan. 13, 1947 INVENTOR. A/bcrf y/e Seba/amd Patentcd Oct. 10, 1950 SOA? TBE'I'ING APPARATUS Albert L. Schulerud, Nutley, N. J., assignor to Colgate-Palmolive-Peet Company, Jersey City, N. J., a corporation of Delaware Application January 13, 1947, Serial No. 721,741

i (ci. ass-8) 2 Claims.

This invention relates to the manufacture of aerated soap and is more particularly concerned with mechanism adapted to be incorporated into usual soap plodder apparatus i for improving aeration of the soap as it passes through the plodder.

The present invention is an improvement over that described'and claimed in my abandoned application, Serial No. 591,937, filed May' 4, 1945. In that application. the aeration of milled soap during its .passage through a generally conventional plodder apparatus is specifically disclosed and claimed.

The present invention contemplates further modification of conventional plodder apparatus forobtaining improved and uniform aeration of the soap during its passage through such apparatus. Speciflcally, I provide special mechanism within the plodder for working and homogenizing plastic aerated soap after it has passed through at least one worm chamber of the plodder. A preferred embodiment of the invention will be disclosed below.

With the above in mind, it is a major object of my invention to provide novel apparatus for improving aeration of soap during plodding.

It is a further object of the invention to provide novel apparatus for incorporation in a soap plodder for improving the dispersion of air in aerated soap wherein a pair of relatively rotatable members form a restricted annular outwardly directed throat through which plastic soap is forced. r

A further object of the invention is to provide a novel soap aeration apparatus wherein soap is passed through. and worked within a restricted annular homogenizing throat composed of a pair of relatively rotatable members having opposed surfaces extending generally in coextensive radial relation.

It is a further object of the invention to provide novel apparatus for incorporation in a soap plodder for improving and obtaining uniformity of the dispersion of air in aerated soap wherein a pair of relatively rotatable members form a restricted annular radiaily and longitudinally outwardiy directed throat through which plastic soap is forccd.

A further object of the invention is to provide a novel soap aeration apparatus wherein soap is passed through and worked within a restricted annular substantially conical homogenising throat composed of a pair of relatively rotatable members having opposed surfaces generally extendim in coextensive radial relation.

Further objects of the invention will presently appear as the description proceeds in connection with the annexed claims and the appended drawings wherein:

Figure 1 is a side elevation 'partly broken away and partly in section. iliustrating a plodder apparatus which is generally conventional but provided adjacent the inner end of the upper worm chamber with aeration improving apparatus according to a preferred embodiment of the invention;

Figure 2 is an enlarged generally perspective view partly broken away and partly in section of the aeration improving apparatus at the inner end of the upper worm of the piodder of Figure 1;

Figure 3 is a fragmentary section illustrating a further embodiment of the invention wherein soap working projections are provided in the throat;

n Figure 4 is a side elevation; partly broken away and partly in section, ilustrating the plodder apparatus provided adiacent the inner end of the upper worm chamber with aeration improving apparatus according to a further embodiment of the invention;

Figura 5 is an enlarged generally perspective view partly broken away and partly in section of the aeration improving apparatus at the inner end of the upper worm of the plodder of Figure 4;

Figure 6 is a fragmentary side elevation mainly in section illustrating a further homogenizing throat construction;

Figure 7 is a fragmentary side elevation mainly in section illustrating a 'stil further homogenizing throat construction; and

Figure 8 is a generally perspective view partly broken away and partly in section illustratmg still another homogenizing throat construction..

The plodder apparatus in which the invention is ipreferably incorporated comprises an upper barrel and a lower barrel il in which are disposed cylindrical bores |3 and ll, respectivelyV Surrounding bores il and H are water Jackets It and IG. respectively, the water jackets spaces for the upper and lower bores being separated by a rlgid diaphragm l'l, and water may be circulated continuously through these separate water Jackets for maintaining the plastic soap passing through bores lt and H at desired temperatures. A worm it. which is rotatabe about a horizontal axis concentric with the axis of bore |3 and which is supported mainly by the walls of upper bore lt, is non-rotatably coupled by an end socket and key |9 to a drive shaft 2| extended through a suitable boss 22 on upper barrel ll. Shaft 2| has aifixed thereto a suitable gear or like drivins device 23. The top of barrel is provided with an aperture 20 through which soap is fed into the plodder.

At the right end of barrel in Figure 1, passage of soap through the bore |3 is opposed by a perforated plate 24 disposed substantially vertically and fixedly mounted in an annular rim member 25 which is swingably or otherwise mounted on the end of barrel to enable plate 24 to be moved away from the end of bore |3. When rim 25 is secured' in place during normal operation, the soap is forced from left to right through bore |3 by rotation of worm 8 and passes as continuous filaments through tapered apertures 26 of plate 24 which is essentially rigid with barrel A suitable multi-bladed radial knife 28 is nonrotatably secured, as by fastening elements indicated at 29, to the inner right hand end of worm |8 just inwardly of plate 24. and knife 28 is so disposed that its radial blades have their smooth sharp edges disposed in a Vertical plane substantially in contact with the inner side of plate 24. Knife 28 thus passes in a substantially scraping relation over the inner face of plate 24 and thereby cuts and works the soap pressed against plate 24 by the action of worm |8. This prevents apertures 26 from becoming clogged, particularly by removing or subdividing any hard large lumps of soap that might accumulate before the inner face of plate 24.

After passing through plate 24I the worked soap which has been considerably compacted and mixed by worm |8 in bore |3 emerges into a space 3| disposed above an opening 32 at the top of the lower barrel |2. Within bore |4 is disposed the lower worm 33 which is supported mainly by the walls of bore |4 and has its right hand end non-rotatably secured, as by key 34, to a drive shaft 35 that extends through a suitable bearing in barrel |2 and has aiiixed thereto a pulley or like drive member 36 for rotating it independently of the rotation of worm |8.

At the left hand end of bore |4 in Figure 1, the soap which has been further compacted and worked by worm 33 and forced from right to left within bore |4 emer'ges through a decreasing conical nozzle 31 containing internal guide bars 38 which oppose the rotation of plastic columnar mass of soap passing through the nozzle. The emerging soap column is formed to any suitable shape in cross section by a suitable plate or frame (not shown) detachably mounted on the end of the nozzle as is usual practice. The soap passes through emergent throat 39, which is surrounded by a cooling or other temperature regulating jacket 4| for accurately controlling the temperature of the surface of the continuously emerging soap column.

The above described apparatus comprises essentially the main components of the conventional type double worm plodder apparatus wherein soap entering through opening 28 in the upper worm barrel is compacted and worked by worm 8 during its passage from left to right in bore |3, this action being aided by the blocking effect of plate 24. The soap under pressure is then forced in the form of filaments through the openings v26 in plate 24 into space 3| and it immediately drops through opening 32 into the lower worm chamber where it is again worked and compacted by the lower worm and finally delivered through throat 38 to emerge as a continuous plastic rectangular soap column. This plodder apparatus is substantially the same as that disclosed in the United States Letters Patent No. 2,148,770 to Schwantes, issued February 14, 1939, to which reference is made for further detail.

In practicing the preferred embodiment of the invention the soap which is passed through the plodder is preferably of a predetermined high moisture content and is also maintained at a correlated predetermined temperature. The present invention is advantageously practiced with milled soap having a moisture content of between 15% and '30% and during its passage through the plodder the soap is maintained at about F. to F. at its point of greatest agitation. i

I have provided an aeration improving apparatus which in the preferred embodiment is located at the outlet end of the upper worm for further working the extruded soap filaments to provide improved and uniform fine dispersion of air in the soap while very probably at the same time increasing the air content of the worked soap and this will now be described.

In its preferred structural embodiment, this homogenizing apparatus comprlses an arrangement for producing a restricted annular throat which opens radially Outwardly to discharge into space 3|, and which is fed internally by soap extruded through the openings 26. During passage through this throat, the soap is worked and kneaded by the relatively rotatable surfaces of the throat.

As in the Schwantes patent, the right hand end of upper worm |8 is provided with tapped bore in which is threaded a bolt 42 projecting axially from worm |8 freely through a suitable enlarged aperture in plate 24. In the said Schwantes patent, the corresponding bolt is provided to fasten a second scraper knife on the outer side of plate 24. but in the preferred structure for practicing the present invention this outer scraper knife is omitted. The outer end of bolt 42 is formed with an axial bore 43 in which is journalled the inner end of a shaft 44 concentrio with bore |3 and supported at its outer end in asuitable bearing on a. rigid frame bracket 45.

Shaft 44 extends through a suitable aperture in a closure 46 that is removably secured, as by bolting, to the plodder barrel structure. Shaft 44 has afiixed to its outer end a pulley 41 which is 'suitably driven. Shaft 44 is rotatable independently of the rotation of worm |8, the latter serving merely to support a pilot bearing for shaft 44. Worm |8, knife 28 and bolt 42 of course rotate as a unit when shaft 2| is rotated, while plate 24 is stationary as in the usual plodder operation.

Outwardly of plate 24, and preferably upon the outer face of rim 25, is disposed a generally vertically arranged vannular sheet metal plate 48 rigidly secured to rim 25 as by spinning an inner perlpheral fiange 48 over the inner circumference of rim 25. Plate 48 thus provides a vertically disposed smooth annular radial face 5| forming one sideof the homogenizing throat. Any other suitable manner of rigidly securing plate 48 to rim 25 may be employed. If desired, moreover, the Outwardly facing annular, smooth radial face 5| may be formed integral with rim 25. In any event face 5| preferably lies in a plane perpendicular to the axis of rotation of worm |8 and outwardly of plate 24.

Shaft M is Vformed with `a .squared portiong! upon which is non-rotatably mounted 'the hub 53 of a metal disk `having at its outer peripheryz a smoothannular radial face '55 co-extensive with stationary face 5| and vforming therewith the annular, radially directed restricted homogenizing throat through which thev soap filaments must pass before entering space 3 I. Preferably the inner -end of hub 53 solidly abuts the corresponding side of plate24, and is formed with a smooth conical surface 56 leading from the hub to face 55. Surface 56 thus effectively `cooperates with the adjacent stationary parts of the plodder to provide a decreasingly tapered annular funnel for directinggzthe extruded filamentary 'massof soap emerging from apertures 26 into the restricted' throat formed by faces 5| 'and 55.

Inv practice, I have found it satisfactory 'to provide the throat with a radial dimension of.

disclosed in my above-identified application;l the r'.

soap 'is .now cons'iderably aerated due to subdivision of the incorporated air bodies and comprises a mass `ofi plastic interlaced cohesive filaments each about one-half an inch in diameter. The soap mass is guided mainly by the conicalv surface '56 upwardly into the relatively narrow pass of the homogenizing throat Adefined by coextensive smooth annular faces5| and 55 that are relatively rotatablesince plate 48 is stationary and disk 54 isrotated through pulley 41. 'The soap mass`` is thus forced radially 'through the homogenizing throat Where it is: worked .and homogenized. `y`Due to the relativ'e rotation; of faces`5|` and `55; the radially moving filamentary soap mass is kneaded and agitated in such man-- ne'r as; to effect improved 'unifoi'm and flnerV dispersio'n of the air within the mass and usually furth'eraer'ation. -Any lumps or solid soap pieces are further broken up and aerated during passage" of 'the soap mass through 'the 'throat. This improves the un'iformityofcolor and texture of yDuring its passage through the homogenizing throat the soap temperature is about 1059 F. toy

125 F.,and in any'event' below 130 F.,'to preventl liquefaction'o'f the soap, thereby renderinglthe soap of'such -plasticity asvto Ahave Optimum air' retentivity. 1 Thefcontrol and selection lof soap' temperature andmoisture content are preferably the same `as inimy above-identifled application.

'Thehomogenized vsoap'mass which. is eventual-v` ly forcedthrough the pouter periphery of the throatyandl cut off `lby'v a :knifev .50 (Figura 2) 1 mountedondisk 54 and .extending over theouter openingof .the throatfalls through space 3| and' opening y`32-into the` lower worm where'it is` worm |8 if vthe `ylatter rotatesfast enough.V as by securing shaft 44 non-rotatably to worm l|8 and omitting pulley 41. It isessential only that they -be yrelative'ly movable sufiiciently to impart adequate rotational mixing forces in co-action with the radial forces which are pressing the soap outwardly through the pass. i

It is also within the scope of the invention to have the pass between the faces 5| and 55 substantially offrusto triangular section as .illusltrated in ``Figure-3; that is, the distance between .faces 5| and 55 over their co-extensive areas may .gradually decrease from the inner periphery to- .Ward .the `outer per-iphery. In this manner, the soap passing through the throat will receive inlcreased working and homogenizing action which .aids in retaining the aerationl while improving `dispersion of the air in the mass. e

Further, if desired and as illustrated Ain Figure 3, -faces 5| and 55, or both, whether parallel or non-parallel, 'may be provided with projections additionally plodded in the usual manner.` By

If vdesired,v anymanner of .accomplishing rela -'z tive rotation between li'faces 5| and -55 can -bev provided. They could-be separately mounted and oppositely. driven,4 `or disk -54 -.could `be' driven by,

or -lugs 51 orroughened areas toA shred and work the soapmore vigorously -in 'order to obtain desired or adequate distributionof air in the mass. The distance between faces 5| and 55 is small enough to permit the necessary working of the soap passing through the throat but,'of course, it should be large .enough so that it will not interfere with continuous fiow of soap through the plodder apparatus. l e -i Figures 4 and 5 illustrate a further embodiment of the invention of somewhat different construction and wherein the aeration improving .device is driven by the upper worm. Parts whichv are the same as in Figures 1-3 are similarly numbered in Figures 4- and 5.

In the embodiment ofi'Figures 4 and 5, this aeration improving apparatus comprises an arrangement'for producing a restricted'annular substantially conical throatV which opens radially` and' longitudinally outwardly to discharge into space 3'|,'and1which is fed internally by soap extruded through the openings 26. -During pasfasten a second scraper knife on .the outer side of plate 24, but in the present-'finvention this outer scraperknife is omitted. An'outer part of bolt 58 'is squared as atz'59 and terminates in a threaded end portion 60. 1 i,

AOutwardly of plate `ZIL'the cylindrical inner periphery of rim'f25-hasrigidly lsecured thereto;

as by zspinning, a cylindrical sleeve .6| which is, rigid andpreferably integral :with an-'outwardly extending, frusto-conical` member. 1.62. Preferably sleeve 6| and cone 62 .are stamped outv ofl Cone 62 is concentric with,`

agsheet vof- `thinl metal. bore |-3, anditsouter edge 63ipreferably-lies |in a plane Derpendicular to the axis of rotation'of worm-18. i i

A second frusto-conical member;64 ofvs maller.

diameter t-han.cone62 vsoas to bejnested .therein is formed.y at' its smaller ,innenend .with afiat radia] hub65 .centrally formedwith a. nonlcir-.,-- cular hole'pressfitted. onto squared. portiqnl59 `of:

worm |8. v-'lI'he axis -of inner cone .54 is coincident; with thezaxi Omnia' mail: and: the 011i??- 'parallel to edge 63.

'I edge 66 of inner cone 64 terminates adjacent and A collar 61 surrounding bolt 59 and abutting against hub 65 and a nut 68 threaded on portion 60 of the bolt maintain cone 64 against longitudinal displacement.

Concentric cones 62 and 64 are so disposed as to be coextensive over their major portlons.'

Inner surface 69 of the outer cone and outer surface of the inner cone'are preferably smooth and preferably disposed at a slight relative angle as illustrated. Ii' desired, they may be parallel or arranged at a greater relative angle than illustrated without departing from the scope of the invention.

The coextensive relatively rotatable cone surfaces define a continuousiy annular, narrow throat which extends radially' and axially or longitudinally outwardly from the space 1| into which the filaments from plate 24 are discharged. This throat, especially where the surfaces 69 and 10 are so angularly disposed as to form a throat of outwardly decreasing size, may be conlsidered to comprise an inner relatively wide area entrance zone 12 where the cones have maximum separation and an outer smaller area or working zone 13 where the cone surfaces approach each other and wherein the passage area between the cones is less than the free area of apertures 26 to insure that the working zone will be always full during operation.

A knife 14 is secured to rotating cone edge 66 and extends closely over adjacent outer cone edge 63 so as to bridge the outlet mouth of the throat and sever the issuing mass therefrom during operation.

The angle A of the throat is not particularly critical, although it has been found that about 45 to 60 is satisfactory and produces best results. The coextensive radial length of the cones is more than four inches and preferably about six to eight inches or more. By changing the angle of the throat, the speed of passage of the soap mass therethrough can be controlled, increased speed, however, representing less working of the mass. An advantage of an angular throat of this kind is to locate the discharge mouth of the aeration throat well out into space 3| and over aperture 32.

While the sides of the throat are illustrated as radially straight, they may either or both .be curved, as for example, instead of a cone at 64, a part-spherical shell could be employed, or both parts 62 and 64 could be arcuate shells of different radii of curvature.

In operation, the warm milled soap introduced through opening 20 is heated and worked while plastic in bore |3 and passed in the form of filaments through apertures 26 in plate 24 into space 1| as above disclosed. and considerably aerated due to subdivision of the incorporated air bodies by knife 28 and the extrusion operation. The partially aerated soap wh*ch now comprises a mass of plastic interlaced cohesive fllaments each about one half an inch in diameter is forced by the worm pressure upwardly into the relatively narrow conical homogenizing pass or throat defined by coextensive smooth annular faces 69 and 10 which are relatively rotatable. Due to the restriction provided by faces 69 and 10, the soap mass is thus forced radially outwardly through the homogenizing throat where it is worked and homogenized. Due to the relative rotation of faces 69 and 10, the radially moving filamentary soap mass is kneaded and agitated in such manner as to efi'ect improved uniform and flner dispersion of the air within the mass and usuaily some further aeration. Any lumps or solid soap pieces are further broken up and aerated during passage of the soap mass through the throat. This improves the uniformity of color and texture of the soap.

As in the earlier described embodiment, during passage through the homogenizing throat the soap temperature is preferably about F. to F., and in any event below F. to prevent liquefaction of the soap, thereby rendering the soap of such plasticity as to have optimum air retentivity.

The homogenized aerated soap mass which is eventually forced through the outer periphery of-the throat and cut off by knife 14 falls through space 3| and opening 32 into the lower worm where it is additionally plodded in the usual manner.

Further, if deslred faces 69 and 10, or both, whether parallel or non-parallel, may be provided with projections or lugs or roughened areas as in Figure 3 to shred and work the soap more vigorously in order to obtain desired or adequate homogenization. The distance between faces 69 and 10 is small enough to permit the necessary working of the soap passing through the throat but, of course, the latter should be large enough so that it will not interfere with continuous flow w with an integral cylindrical support sleeve 16V mounted on rim 25 similarly to cone 62 of Figure 5 except that cone 15 isdisposed axially outwardly a greater distance than cone 62. This member is preferably a sheet metal stamping.

A bolt 11, protruding from the end of worm IB like bolt 58 but shorter than bolt 58, is formed with a collar 18 and a threaded end 19. A second generally frusto-conical member indicated at 00 is formed with a flat inner end 8| apertured to fit by collar 18 and a nut 82.

Member 00 is formed with an inner relatively steep frusto-conical section 63 and an outer frusto-conical section 84 which is disposed adjacent to cone 15 and substantially coextensive therewith. Preferably the space between cones 15 and 8| progressively decreases outwardly toward the exit mouth of the homogenizing pass. Since member 80 rotates with worm l8. the pass between cones 15 and 84 constitutes a homogenizing pass like those above described.

In operation, the extrudecl filamentary plastic mass is guided by sleeve 16 and steep cone 83 into the entrance mouth of 'the homogenizing pass. The arrangement is such that, although thelcones are nested within a relatively small axial space, the inner end of member 80, because of steep cone 83, does not block passage of the soap through plate 2|.

Figure 7 illustrates another embodiment of the invention wherein the nested members of the homogenizing throat are shaped to afl'ord optimum working in a relatively short axial space. Outer member 85 comprlses a cylindrical sleeve 86 and a frusto-conical section 91. This is similar to the outer cone of Figure 4, but cone 81 is extended inwardly toward plate 24 to provide an additional frusto-conical section 88 which is a continuation of cone 81. An internal conical wall 89 is reversely inclined to cone 81, 88 closes the space between the inner end of cone 88 and the outer periphery of plate 24.

The inner member 90 comprises a fiat end 9| centrally apertured to be non-rotatably secured upon a bolt 92 rotatable with worm l8. The outer conical section 93 of member 18 is adjacent and substantially coextensive with cone 81, 88 the distance between the cones preferably decreasing slightly toward their outer peripheries.

In operation, the plastic filamentary mass extruded from plate 24 is guided into the entrance mouth of the homogenizing pass between the relatively rotatable cones and is homogenized to obtain a finer dispersion of air therein as in the above examples. This arrangement enables a relatively long homogenizing pass to be obtained within a relatively short axial space, and

the provision of wall 89 insures against trapping of any part of the mass within the device.

Figure 8 illustrates still another embcdiment of the invention wherein the homogenizing throat comprises an annular passage 94 bounded by coa'xially disposed, relatively movable cylindrical members 95 and 96` Projections or lugs 91 and 98 are arranged in transverse rows within the throat and adjacent rows fastened to opposite cylinders, so that the Iugs 91 turn with the inner cylinder 95 and the lugs 98 remain stationary with the outer cylinder 96, the combination causing a shearing action upon the soap during normal operation.

The invention may also be carried out with one or both of the members 95 and 96 tapered so as to progressively decrease the cross-sectional area of the throat. Shea'ring action may also be accomplished with no lugs attached to the outer cylinder by having lug rows fastened to a plurality of relatively movable disc or cylindrical members comprising the inner boundary of the annular passage.

Except for the above described differences in structure, the embodiments of Figures 6 and 7 are the same as that of Figures 4 and 5. It will be understood that parts of the various embodiments may be used in the other embodiments without departing from the spirit of the invention.

It will be understood that the term soap as used herein includes all soaps, detergents and similar compounds. It will further be understood that the term aeratlng includes the inclusion of air or any gas into the soap.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics. thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive,

'the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

, What is claimed and desired to be secured by the United States Letters Patent is:

1. An apparatus for producing aerated bar soap comprising a barrel having an opening for the introduction of soap, a worm rotatable within said barrel for compacting and working said soap, means for heating the soap in said barrel during said working to maintain it plastic to retain incorporated air bodies, a homogenizing throat mounted at the discharge end of said barrel comprising relatively rotatable members between which said soap is forced under worm generated pressure and further worked to subdivide the air bodies therein, and means for compacting said soap discharged from said throat and extruding it as a continuous bar without substantial deaeration thereof.

2. An apparatus for producing aerated soap in bar form comprising a cylinder, a worm in said cylinder, an inlet into said cylinder adjacent to one end thereof for partioles of solid soap and entrained air, means for heating soap in said cylinder, a foraminous outlet at the other `end of said cylinder, means to rotate said worm Whereby working of the heated soap particles subdivides the air and disperses it through a matrix of solid soap, means associated with the said other end of said cylinder into which filaments of soap from said foraminous outlet discharge defining an outwardly directed, open ended, narrow, continuously annular homogenizing throat having relatively rotatable sides through which said soap'is forced by pressure generated by said worm and thereby worked to further subdivide said air, and means for compacting soap discharged from said throat into a continuous bar without substantial deaeration thereof.

ALBERT L. SCHULERUD.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,988,743 MacKenzie Jan. 22, 1935 2,115,l23 Russell Apr. 26, 1938 2,146,770 Schwantes Feb. 14, 1939 2,172.704 Gentilll Sept. 12, 1939 l FOREIGN PATENTS Number Country Date 806,149' France Dec. 8. 1936 

